High power laser energy distribution patterns, apparatus and methods for creating wells

ABSTRACT

There is provided a system, apparatus and methods for providing a laser beam to borehole surface in a predetermined and energy deposition profile. The predetermined energy deposition profiles may be uniform or tailored to specific downhole applications. Optic assemblies for obtaining these predetermined energy deposition profiles are further provided.

This application is a continuation of Ser. No. 12/544,094 filed Aug. 19,2008 and which claims the benefit of priority of provisionalapplications: Ser. No. 61/090,384 filed Aug. 20, 2008, titled System andMethods for Borehole Drilling: Ser. No. 61/102,730 filed Oct. 3, 2008,titled Systems and Methods to Optically Pattern Rock to Chip RockFormations; Ser. No. 61/106,472 filed Oct. 17, 2008, titled Transmissionof High Optical Power Levels via Optical Fibers for Applications such asRock Drilling and Power Transmission; and, Ser. No. 61/153,271 filedFeb. 17, 2009, title Method and Apparatus for an Armored High PowerOptical Fiber for Providing Boreholes in the Earth, the disclosures ofwhich are incorporated herein by reference.

This invention was made with Government support under Award DE-AR0000044awarded by the Office of ARPA-E U.S. Department of Energy. TheGovernment has certain rights in this invention.

BACKGROUND OF THE INVENTION

The present invention relates to methods, apparatus and systems fordelivering high power laser energy over long distances, whilemaintaining the power of the laser energy to perform desired tasks. In aparticular, the present invention relates to optics, beam profiles andlaser spot patterns for use in and delivery from a laser bottom holeassembly (LBHA) for delivering high power laser energy to the bottom ofa borehole to create and advance a borehole in the earth.

In general, boreholes have been formed in the earth's surface and theearth, i.e., the ground, to access resources that are located at andbelow the surface. Such resources would include hydrocarbons, such asoil and natural gas, water, and geothermal energy sources, includinghydrothermal wells. Boreholes have also been formed in the ground tostudy, sample and explore materials and formations that are locatedbelow the surface. They have also been formed in the ground to createpassageways for the placement of cables and other such items below thesurface of the earth.

The term borehole includes any opening that is created in the groundthat is substantially longer than it is wide, such as a well, a wellbore, a well hole, and other terms commonly used or known in the art todefine these types of narrow long passages in the earth. Althoughboreholes are generally oriented substantially vertically, they may alsobe oriented on an angle from vertical, to and including horizontal.Thus, using a level line as representing the horizontal orientation, aborehole can range in orientation from 0° i.e., a vertical borehole, to90°,i.e., a horizontal borehole and greater than 90° e.g., such as aheel and toe. Boreholes may further have segments or sections that havedifferent orientations, they may be arcuate, and they may be of theshapes commonly found when directional drilling is employed. Thus, asused herein unless expressly provided otherwise, the “bottom” of theborehole, the “bottom” surface of the borehole and similar terms referto the end of the borehole, i.e., that portion of the borehole farthestalong the path of the borehole from the borehole's opening, the surfaceof the earth, or the borehole's beginning.

Advancing a borehole means to increase the length of the borehole. Thus,by advancing a borehole, other than a horizontal one, the depth of theborehole is also increased. Boreholes are generally formed and advancedby using mechanical drilling equipment having a rotating drilling bit.The drilling bit is extending to and into the earth and rotated tocreate a hole in the earth. In general, to perform the drillingoperation a diamond tip tool is used. That tool must be forced againstthe rock or earth to be cut with a sufficient force to exceed the shearstrength of that material. Thus, in conventional drilling activitymechanical forces exceeding the shear strength of the rock or earth mustbe applied to that material. The material that is cut from the earth isgenerally known as cuttings, i.e., waste, which may be chips of rock,dust, rock fibers, and other types of materials and structures that maybe created by thermal or mechanical interactions with the earth. Thesecuttings are typically removed from the borehole by the use of fluids,which fluids can be liquids, foams or gases.

In addition to advancing the borehole, other types of activities areperformed in or related to forming a borehole, such as, work over andcompletion activities. These types of activities would include forexample the cutting and perforating of casing and the removal of a wellplug. Well casing, or casing, refers to the tubulars or other materialthat are used to line a wellbore. A well plug is a structure, ormaterial that is placed in a borehole to fill and block the borehole. Awell plug is intended to prevent or restrict materials from flowing inthe borehole.

Typically, perforating, i.e., the perforation activity, involves the useof a perforating tool to create openings, e.g. windows, or a porosity inthe casing and borehole to permit the sought after resource to flow intothe borehole. Thus, perforating tools may use an explosive charge tocreate, or drive projectiles into the casing and the sides of theborehole to create such openings or porosities.

The above mentioned conventional ways to form and advance a borehole arereferred to as mechanical techniques, or mechanical drilling techniques,because they require a mechanical interaction between the drillingequipment, e.g., the drill bit or perforation tool, and the earth orcasing to transmit the force needed to cut the earth or casing.

It has been theorized that lasers could be adapted for use to form andadvance a borehole. Thus, it has been theorized that laser energy from alaser source could be used to cut rock and earth through spalling,thermal dissociation, melting, vaporization and combinations of thesephenomena. Melting involves the transition of rock and earth from asolid to a liquid state. Vaporization involves the transition of rockand earth from either a solid or liquid state to a gaseous state.Spalling involves the fragmentation of rock from localized heat inducedstress effects. Thermal dissociation involves the breaking of chemicalbonds at the molecular level.

To date it is believed that no one has succeeded in developing andimplementing these laser drilling theories to provide an apparatus,method or system that can advance a borehole through the earth using alaser, or perform perforations in a well using a laser. Moreover, todate it is believed that no one has developed the parameters, and theequipment needed to meet those parameters, for the effective cutting andremoval of rock and earth from the bottom of a borehole using a laser,nor has anyone developed the parameters and equipment need to meet thoseparameters for the effective perforation of a well using a laser.Further is it believed that no one has developed the parameters,equipment or methods need to advance a borehole deep into the earth, todepths exceeding about 300 ft (0.09 km), 500 ft (0.15 km), 1000 ft,(0.30 km), 3,280 ft (1 km), 9,840 ft (3 km) and 16,400 ft (5 km), usinga laser. In particular, it is believed that no one has developedparameters, equipments, or methods nor implemented the delivery of highpower laser energy, i.e., in excess of 1 kW or more to advance aborehole within the earth.

While mechanical drilling has advanced and is efficient in many types ofgeological formations, it is believed that a highly efficient means tocreate boreholes through harder geologic formations, such as basalt andgranite has yet to be developed. Thus, the present invention providessolutions to this need by providing parameters, equipment and techniquesfor using a laser for advancing a borehole in a highly efficient mannerthrough harder rock formations, such as basalt and granite.

The environment and great distances that are present inside of aborehole in the earth can be very harsh and demanding upon opticalfibers, optics, and packaging. Thus, there is a need for methods and anapparatus for the deployment of optical fibers, optics, and packaginginto a borehole, and in particular very deep boreholes, that will enablethese and all associated components to withstand and resist the dirt,pressure and temperature present in the borehole and overcome ormitigate the power losses that occur when transmitting high power laserbeams over long distances. The present inventions address these needs byproviding a long distance high powered laser beam transmission means.

It has been desirable, but prior to the present invention believed tohave never been obtained, to deliver a high power laser beam over adistance within a borehole greater than about 300 ft (0.90 km), about500 ft (0.15 km), about 1000 ft, (0.30 km), about 3,280 ft (1 km), about9,8430 ft (3 km) and about 16,400 ft (5 km) down an optical fiber in aborehole, to minimize the optical power losses due to non-linearphenomenon, and to enable the efficient delivery of high power at theend of the optical fiber. Thus, the efficient transmission of high powerfrom point A to point B where the distance between point A and point Bwithin a borehole greater than about 1,640 ft (0.5 km) has long beendesirable, but prior to the present invention is believed to have neverbeen obtainable and specifically believed to have never been obtained ina borehole drilling activity. The present invention addresses this needby providing an LBHA and laser optics to deliver a high powered laserbeam to downhole surfaces in a borehole.

A conventional drilling rig, which delivers power from the surface bymechanical means, must create a force on the rock that exceeds the shearstrength of the rock being drilled. Although a laser has been shown toeffectively spall and chip such hard rocks in the laboratory underlaboratory conditions, and it has been theorized that a laser could cutsuch hard rocks at superior net rates than mechanical drilling, to dateit is believed that no one has developed the apparatus systems ormethods that would enable the delivery of the laser beam to the bottomof a borehole that is greater than about 1,640 ft (0.5 km) in depth withsufficient power to cut such hard rocks, let alone cut such hard rocksat rates that were equivalent to and faster than conventional mechanicaldrilling. It is believed that this failure of the art was a fundamentaland long standing problem for which the present invention provides asolution.

The environment and great distances that are present inside of aborehole in the earth can be harsh and demanding upon optics and opticalfibers. Thus, there is a need for methods and an apparatus for thedelivery of high power laser energy very deep in boreholes that willenable the delivery device to withstand and resist the dirt, pressureand temperature present in the borehole. The present invention addressesthis need by providing an LBHA and laser optics to deliver a highpowered laser beam to downhole surfaces of a borehole.

Thus the present invention addresses and provides solutions to these andother needs in the drilling arts by providing, among other thingsoptics, beam profiles and laser spot patterns for use in and deliveryfrom an LBHA to provide the delivery of high powered laser beam energyto the surfaces of a borehole.

SUMMARY

It is desirable to develop systems and methods that provide for thedelivery of high power laser energy to the bottom of a deep borehole toadvance that borehole at a cost effect rate, and in particular, to beable to deliver such high power laser energy to drill through rock layerformations including granite, basalt, sandstone, dolomite, sand, salt,limestone, rhyolite, quartzite and shale rock at a cost effective rate.More particularly, it is desirable to develop systems and methods thatprovide for the ability to be able to deliver such high power laserenergy to drill through hard rock layer formations, such as granite andbasalt, at a rate that is superior to prior conventional mechanicaldrilling operations. The present invention, among other things, solvesthese needs by providing the system, apparatus and methods taughtherein.

Thus, there is provided a system for creating a borehole in the earthhaving a high power laser source, a bottom hole assembly and, a fiberoptically connecting the laser source with the bottom hole assembly,such that a laser beam from the laser source is transmitted to thebottom hole assembly the bottom hole assembly comprising: a means forproviding the laser beam to a bottom surface of the borehole; theproviding means comprising beam power deposition optics; wherein, thelaser beam as delivered from the bottom hole assembly illuminates thebottom surface of the borehole with a substantially even energydeposition profile.

There is further provided a system for creating a borehole in the earthcomprising: a high power laser source; a bottom hole assembly; anoptical fiber, having a first and a second end, having a length betweenthe first and second ends, the first end being optically associated withthe laser source and the fiber having a length of at least about 1000ft; a means for delivering a laser beam from the laser source to asurface of the borehole; the laser delivery means connected to andoptically associated with the second end of the optical fiber; and, ameans for providing a substantially uniform energy deposition.

There is additionally provided a system and method for creating aborehole in the earth wherein the system and method employ means forproviding the laser beam to the bottom surface in a predetermined energydeposition profile, including having the laser beam as delivered fromthe bottom hole assembly illuminating the bottom surface of the boreholewith a predetermined energy deposition profile, illuminating the bottomsurface with an any one of or combination of: a predetermined energydeposition profile biased toward the outside area of the boreholesurface; a predetermined energy deposition profile biased toward theinside area of the borehole surface; a predetermined energy depositionprofile comprising at least two concentric areas having different energydeposition profiles; a predetermined energy deposition profile providedby a scattered laser shot pattern; a predetermined energy depositionprofile based upon the mechanical stresses applied by a mechanicalremoval means; a predetermined energy deposition profile having at leasttwo areas of differing energy and the energies in the areas correspondinversely to the mechanical forces applied by a mechanical means.

There is yet further provided a method of advancing a borehole using alaser, the method comprising: advancing a high power laser beamtransmission means into a borehole; the borehole having a bottomsurface, a top opening, and a length extending between the bottomsurface and the top opening of at least about 1000 feet; thetransmission means comprising a distal end, a proximal end, and a lengthextending between the distal and proximal ends, the distal end beingadvanced down the borehole; the transmission means comprising a meansfor transmitting high power laser energy; providing a high power laserbeam to the proximal end of the transmission means; transmittingsubstantially all of the power of the laser beam down the length of thetransmission means so that the beam exits the distal end; transmittingthe laser beam from the distal end to an optical assembly in a laserbottom hole assembly, the laser bottom hole assembly directing the laserbeam to the bottom surface of the borehole; and, providing apredetermined energy deposition profile to the bottom of the borehole;whereby the length of the borehole is increased, in part, based upon theinteraction of the laser beam with the bottom of the borehole.

Moreover there is provided a method of advancing a borehole using alaser, wherein the laser beam is directed to the bottom surface of theborehole in a substantially uniform energy deposition profile andthereby the length of the borehole is increased, in part, based upon theinteraction of the laser beam with the bottom of the borehole.

Still further there is provided a method of advancing a borehole using alaser, wherein the laser beam is directed in a predetermined pattern toprovide a predetermined energy deposition profile to the bottom surfaceof the borehole whereby the length of the borehole is increased, inpart, based upon the interaction of the laser beam with the bottom ofthe borehole.

The foregoing systems and methods may further employ more than one laserbeams, a plurality of laser beams, a laser beam with a Gaussian profileat the fiber bottom hole assembly connection, a substantially Gaussianprofile at the fiber bottom hole assembly connection, a super-Gaussianprofile at the fiber bottom hole assembly connection, or a laser beamwith substantially uniform profile at the fiber bottom hole assemblyconnection.

The forgoing systems and methods may also employ a laser delivery meanscomprising an optical assembly, a rotating optical assembly, a mudmotor, a micro-optics array, or an axicon lens.

The forgoing systems and methods may further employ a laser beam havingat least about 1 kW, 3 kW, 5 kW, 10 kW, or 15 kW at the down hole end ofthe fiber. These systems and methods may employ laser sources from atleast about 5 kW to about 20 kW, at least about 15 kW, at least about 5kW.

One of ordinary skill in the art will recognize, based on the teachingsset forth in these specifications and drawings, that there are variousembodiments and implementations of these teachings to practice thepresent invention. Accordingly, the embodiments in this summary are notmeant to limit these teachings in any way.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B, is a graphic representation of an example of a laserbeam basalt illumination.

FIGS. 2A and 2B illustrate the energy deposition profile of anelliptical spot rotated about its center point for a beam that is eitheruniform or Gaussian.

FIG. 3A shows the energy deposition profile with no rotation.

FIG. 3B shows the substantially even and uniform energy depositionprofile upon rotation of the beam that provides the energy depositionprofile of FIG. 3A.

FIGS. 4A to 4D illustrate an optical assembly.

FIG. 5 illustrates an optical assembly.

FIG. 6 illustrates an optical assembly.

FIGS. 7A and 7B illustrate optical assemblies.

FIG. 8 illustrates a multi-rotating laser shot pattern.

FIG. 9 illustrates an elliptical shaped shot.

FIG. 10 illustrates a rectangular shaped spot.

FIG. 11 illustrates a multi-shot shot pattern.

FIG. 12 illustrates a shot pattern.

FIG. 13A is a perspective view of an LBHA.

FIG. 13B is a cross sectional view of the LBHA of FIG. 13A taken alongB-B.

FIG. 14 is a laser drilling system.

FIGS. 15 to 25 illustrate LBHAs.

DESCRIPTION OF THE DRAWINGS AND THE PREFERRED EMBODIMENTS

In general, the present inventions relate to methods, apparatus andsystems for use in laser drilling of a borehole in the earth, andfurther, relate to equipment, methods and systems for the laseradvancing of such boreholes deep into the earth and at highly efficientadvancement rates. These highly efficient advancement rates areobtainable in part because the present invention provides for optics,beam profiles and laser spot patterns for use in and delivery from alaser bottom hole assembly (LBHA) that shapes and delivers the highpower laser energy to the surfaces of the borehole. As used herein theterm “earth” should be given its broadest possible meaning (unlessexpressly stated otherwise) and would include, without limitation, theground, all natural materials, such as rocks, and artificial materials,such as concrete, that are or may be found in the ground, includingwithout limitation rock layer formations, such as, granite, basalt,sandstone, dolomite, sand, salt, limestone, rhyolite, quartzite andshale rock.

In general, one or more laser beams generated or illuminated by one ormore lasers may spall, vaporize or melt material such as rock or earth.The laser beam may be pulsed by one or a plurality of waveforms or itmay be continuous. The laser beam may generally induce thermal stress ina rock formation due to characteristics of the rock including, forexample, the thermal conductivity. The laser beam may also inducemechanical stress via superheated steam explosions of moisture in thesubsurface of the rock formation. Mechanical stress may also be inducedby thermal decomposition and sublimation of part of the in situ mineralsof the material. Thermal and/or mechanical stress at or below alaser-material interface may promote spallation of the material, such asrock. Likewise, the laser may be used to effect well casings, cement orother bodies of material as desired. A laser beam may generally act on asurface at a location where the laser beam contacts the surface, whichmay be referred to as a region of laser illumination. The region oflaser illumination may have any preselected shape and intensitydistribution that is required to accomplish the desired outcome, thelaser illumination region may also be referred to as a laser beam spot.Boreholes of any depth and/or diameter may be formed, such as byspalling multiple points or layers. Thus, by way of example, consecutivepoints may be targeted or a strategic pattern of points may be targetedto enhance laser/rock interaction. The position or orientation of thelaser or laser beam may be moved or directed so as to intelligently actacross a desired area such that the laser/material interactions are mostefficient at causing rock removal.

Generally in downhole operations including drilling, completion, andworkover, the bottom hole assembly is an assembly of equipment thattypically is positioned at the end of a cable, wireline, umbilical,string of tubulars, string of drill pipe, or coiled tubing and is lowerinto and out of a borehole. It is this assembly that typically isdirectly involved with the drilling, completion, or workover operationand facilitates an interaction with the surfaces of the borehole,casing, or formation to advance or otherwise enhance the borehole asdesired.

In general, the LBHA may contain an outer housing that is capable ofwithstanding the conditions of a downhole environment, a source of ahigh power laser beam, and optics for the shaping and directing a laserbeam on the desired surfaces of the borehole, casing, or formation. Thehigh power laser beam may be greater than about 1 kW, from about 2 kW toabout 20 kW, greater than about 5 kW, from about 5 kW to about 10 kW, atleast about 10 kW, preferably at least about 15 kW, and more preferablyat least about 20 kW. The assembly may further contain or be associatedwith a system for delivering and directing fluid to the desired locationin the borehole, a system for reducing or controlling or managing debrisin the laser beam path to the material surface, a means to control ormanage the temperature of the optics, a means to control or manage thepressure surrounding the optics, and other components of the assembly,and monitoring and measuring equipment and apparatus, as well as, othertypes of downhole equipment that are used in conventional mechanicaldrilling operations. Further, the LBHA may incorporate a means to enablethe optics to shape and propagate the beam which for example wouldinclude a means to control the index of refraction of the environmentthrough which the laser is propagating. Thus, as used herein the termscontrol and manage are understood to be used in their broadest sense andwould include active and passive measures as well as design choices andmaterials choices.

The LBHA should be construed to withstand the conditions found inboreholes including boreholes having depths of about 1,640 ft (0.5 km)or more, about 3,280 ft (1 km) or more, about 9,830 ft (3 km) or more,about 16,400 ft (5 km) or more, and up to and including about 22,970 ft(7 km) or more. While drilling, i.e. advancement of the borehole, istaking place the desired location in the borehole may have dust,drilling fluid, and/or cuttings present. Thus, the LBHA should beconstructed of materials that can withstand these pressures,temperatures, flows, and conditions, and protect the laser optics thatare contained in the LBHA. Further, the LBHA should be designed andengineered to withstand the downhole temperatures, pressures, and flowsand conditions while managing the adverse effects of the conditions onthe operation of the laser optics and the delivery of the laser beam.

The LBHA should also be constructed to handle and deliver high powerlaser energy at these depths and under the extreme conditions present inthese deep downhole environments. Thus, the LBHA and its laser opticsshould be capable of handling and delivering laser beams having energiesof 1 kW or more, 5 kW or more, 10 kW or more and 20 kW or more. Thisassembly and optics should also be capable of delivering such laserbeams at depths of about 1,640 ft (0.5 km) or more, about 3,280 ft (1km) or more, about 9,830 ft (3 km) or more, about 16,400 ft (5 km) ormore, and up to and including about 22,970 ft (7 km) or more.

The LBHA should also be able to operate in these extreme downholeenvironments for extended periods of time. The lowering and raising of abottom hole assembly has been referred to as tripping in and trippingout. While the bottom hole assembling is being tripped in or out theborehole is not being advanced. Thus, reducing the number of times thatthe bottom hole assembly needs to be tripped in and out will reduce thecritical path for advancing the borehole, i.e., drilling the well, andthus will reduce the cost of such drilling. (As used herein the criticalpath referrers to the least number of steps that must be performed inserial to complete the well.) This cost savings equates to an increasein the drilling rate efficiency. Thus, reducing the number of times thatthe bottom hole assembly needs to be removed from the borehole directlycorresponds to reductions in the time it takes to drill the well and thecost for such drilling. Moreover, since most drilling activities arebased upon day rates for drilling rigs, reducing the number of days tocomplete a borehole will provided a substantial commercial benefit.Thus, the LBHA and its laser optics should be capable of handling anddelivering laser beams having energies of 1 kW or more, 5 kW or more, 10kW or more and 20 kW or more at depths of about 1,640 ft (0.5 km) ormore, about 3,280 ft (1 km) or more, about 9,830 ft (3 km) or more,about 16,400 ft (5 km) or more, and up to and including about 22,970 ft(7 km) or more, for at least about ½ hr or more, at least about 1 hr ormore, at least about 2 hours or more, at least about 5 hours or more,and at least about 10 hours or more, and preferably longer than anyother limiting factor in the advancement of a borehole. In this wayusing the LBHA of the present invention could reduce tripping activitiesto only those that are related to casing and completion activities,greatly reducing the cost for drilling the well.

By way of example, and without limitation to other spot and beamparameters and combinations thereof, the LBHA and optics should becapable of creating and maintain the laser beam parameters set out inTable 1 in deep downhole environments.

TABLE 1 Exam- ple Laser Beam Parameters 1 Beam Spot Size 0.3585″,(0.0625″, (12.5 mm-0.5 mm), 0.1″, (circular or (elliptical)) ExposureTimes 0.05 s, 0.1 s, 0.2 s, 0.5 s, 1 s Time-average 0.25 kW, 0.5 kW, 1.6kW, 3 kW, 5 kW Power 2 Beam Type CW/Collimated Beam Spot Size 0.0625″(12.5 mm × 0.5 mm), 0.1″ (circular or (elliptical)) Power 0.25 kW, 0.5kW, 1.6 kW, 3 kW, 5 kW 3 Beam Type CW/Collimated and Pulsed atSpallation Zones Specific Power Spallation zones (920 W/cm2 at ~2.6kJ/cc for Sandstone &4 kW/cm2 at ~0.52 kJ/cc for Limestone) Beam Size12.5 mm × 0.5 mm 4 Beam Type CW/Collimated or Pulsed atSpallation ZonesSpecific Power Spallation zones (~920 W/cm2 at ~2.6 kJ/cc for Sandstone&4 kW/cm2 at ~0.52 kJ/cc for Limestone) Beam Size 12.5 mm × 0.5 mm 5Beam Type CW/Collimated or Pulsed at Spallation Zones Specific PowerSpallation zones {~920 W/cm2 at −2.6 kJ/cc for Sandstone &4 kW/cm2 at~0.52 kJ/cc for Limestone) Beam Size 12.5 mm × 0.5 mm 6 Beam TypeCW/Collimated or Pulsed at Spallation Zones Specific Power illuminationzones {~10,000 W/cm2 at −1 kJ/cc for Sandstone & 10,000 W/cm2 at ~5kJ/cc for Limestone) Beam Size 50 mm × 10 mm; 50 mm × 0.5 mm; 150 mm ×0.5 mm

In general, the energy distribution of the laser beam when itilluminates the material in the borehole to be removed, such as rock orcasing, is important to maximizing the efficiency and rate of removal ofmaterial and the advancement of the borehole. The most desirable beamenergy distribution is dependent upon, among other facts, the downholeconditions, the beam profile at the bottom of the borehole, the spotshape and whether the spot is rotated, scanned, fixed or a combinationof these. Thus, various optical systems and combination of optics areprovide herein to take a particular laser beam profile from the downholeend of a fiber and provided a desired output and energy profile on theborehole surface.

In FIGS. 1A and 1B, there is provided a graphic representation of anexample of a laser beam—borehole surface interaction. Thus, there isshown a laser beam 1000, an area of beam illumination 1001, i.e., a spot(as used herein unless expressly provided otherwise the term “spot” isnot limited to a circle), on a borehole wall or bottom 1002. There isfurther provided in FIG. 1B a more detailed representation of theinteraction and a corresponding chart 1010 categorizing the stresscreated in the area of illumination. Chart 1010 provides von MisesStress in σ_(M) 10⁸ N/m² wherein the cross hatching and shadingcorrespond to the stress that is created in the illuminated area for a30 mill-second illumination period, under down hole conditions of 2000psi and a temperature of 150F, with a beam having a fluence of 2 kW/cm².Under these conditions the compressive strength of basalt is about2.6×10⁸ N/m², and the cohesive strength is about 0.66×10⁸ N/m². Thus,there is shown a first area 1005 of relative high stress, from about4.722 to 5.211×10⁸ N/m², a second area 1006 of relative stress at orexceeding the compressive stress of basalt under the downholeconditions, from about 2.766 to 3.255×10⁸ N/m², a third area 1007 ofrelative stress about equal to the compressive stress of basalt underthe downhole conditions, from about 2.276 to 2.766×10⁸ N/m², a fourtharea 1008 of relative lower stress that is below the compressive stressof basalt under the downhole conditions yet greater than the cohesivestrength, from about 2.276 to 2.766×10⁸ N/m², and a fifth area 1009 ofrelative stress that is at or about the cohesive strength of basaltunder the downhole conditions, from about 0.320 to 0.899×10⁸ N/m².

Accordingly, the profiles of the beam interaction with the borehole toobtain a maximum amount of stress in the borehole in an efficientmanner, and thus, increase the rate of advancement of the borehole canbe obtained. Thus, for example if an elliptical spot is rotated aboutits center point for a beam that is either uniform or Gaussian theenergy deposition profile is illustrated in FIGS. 2A and 2B. Where thearea of the borehole from the center point of the beam is shown as x andy axes 2001 and 2002 and the amount of energy deposited is shown on thez axis 2003. From this it is seen that inefficiencies are present in thedeposition of energy to the borehole, with the outer sections of theborehole 2005 and 2006 being the limiting factor in the rate ofadvancement.

Thus, it is desirable to modify the beam deposition profile to obtain asubstantially even and uniform deposition profile upon rotation of thebeam. An example of such a preferred beam deposition profile is providedin FIGS. 3A and 3B, where FIG. 3A shows the energy deposition profilewith no rotation, and FIG. 3B shows the energy deposition profile whenthe beam profile of 3A is rotated through one rotation, i.e., 360degrees; having x and y axes 3001 and 3002 and energy on z axis 3003.This energy deposition distribution would be considered substantiallyuniform.

To obtain this preferable beam energy profile there are providedexamples of optical assemblies that may be used with a LBHA. Thus,Example 1 is illustrated in FIGS. 4A to 4D, having x and y axes 4001 and4002 and z axis 4003, wherein there is provided a laser beam 4005 havinga plurality of rays 4007. The laser beam 4005 enters an optical assembly4020, having a collimating lens 4009, having input curvature 4011 and anoutput curvature 4013. There is further provided an axicon lens 4015 anda window 4017. The optical assembly of Example 1 would provide a desiredbeam intensity profile from an input beam having a substantiallyGaussian, Gaussian, or super-Gaussian distribution for applying the beamspot to a borehole surface 4030.

Example 2 is illustrated in FIG. 5 and has an optical assembly 5020 forproviding the desired beam intensity profile of FIG. 3A and energydeposition of FIG. 3B to a borehole surface from a laser beam having auniform distribution. Thus, there is provided in Example 2 a laser beam5005 having a uniform profile and rays 5007, that enters a sphericallens 5013, which collimates the output of the laser from the downholeend of the fiber, the beam then exits 5013 and enters a toroidal lens5015, which has power in the x-axis to form the minor-axis of theelliptical beam. The beam then exits 5015 and enters a pair ofaspherical toroidal lens 5017, which has power in the y-axis to map they-axis intensity profiles form the pupil plane to the image plane. Thebeam then exits the lens 5017 and enters flat window 5019, whichprotects the optics from the outside environment.

Example 3 is illustrated in FIG. 6, which provides a further opticalassembly for providing predetermined beam energy profiles. Thus, thereis provided a laser beam 6005 having rays 6007, which enters collimatinglens 6009, spot shape forming lens 6011, which is preferably an ellipse,and a micro optic array 6013. The micro optic array 6013 may be amicro-prism array, or a micro lens array. Further the micro optic arraymay be specifically designed to provide a predetermined energydeposition profile, such as the profile of FIG. 3.

Example 4 is illustrated in FIG. 7, which provides an optical assemblyfor providing a predetermined beam pattern. Thus, there is provided alaser beam 7005, exiting the downhole end of fiber 7040, having rays6007, which enters collimating lens 6009, a diffractive optic 7011,which could be a micro optic, or a corrective optic to a micro optic,that provides pattern 7020, which may but not necessary pass throughreimaging lens 7013, which provides pattern 7021.

There is further provided shot patterns for illuminating a boreholesurface with a plurality of spots in a multi-rotating pattern.Accordingly in FIG. 8 there is provided a first pair of spots 8003,8005, which illuminate the bottom surface 8001 of the borehole. Thefirst pair of spots rotate about a first axis of rotation 8002 in thedirection of rotation shown by arrow 8004 (the opposite direction ofrotation is also contemplated herein). There is provided a second pairof spots 8007, 8009, which illuminate the bottom surface 8001 of theborehole. The second pair of shots rotate about axis 8006 in thedirection of rotation shown by arrow 8008 (the opposite direction ofrotation is also contemplated herein). The distance between the spots ineach pair of spots may be the same or different. The first and secondaxis of rotation simultaneously rotate around the center of the borehole8012 in a rotational direction, shown by arrows 8012, that is preferablyin counter-rotation to the direction of rotation 8008, 8004. Thus,preferably although not necessarily, if 8008 and 8004 are clockwise,then 8012 should be counter-clockwise. This shot pattern provides for asubstantially uniform energy deposition.

There is illustrated in FIG. 9 an elliptical shot pattern of the generaltype discussed with respect to Examples 1 to 3 having a center 9001, amajor axis 9002, a minor axis 9003 and is rotated about the center. Inthis way the major axis of the spot would generally correspond to thediameter of the borehole, ranging from any known or contemplateddiameters such as about 30, 20, 17½, 13⅜, 12¼, 9⅝, 8½, 7, and 6¼ inches.

There is further illustrated in FIG. 10 a rectangular shaped spot 1001that would be rotated around the center of the borehole. There isillustrated in FIG. 11 a pattern 1101 that has a plurality of individualshots 1102 that may be rotated, scanned or moved with respect to theborehole to provide the desired energy deposition profile. The isfurther illustrated in FIG. 12 a squared shot 1201 that is scanned 1201in a raster scan matter along the bottom of the borehole, further acircle, square or other shape shot may be scanned.

The LBHA, by way of example, may include one or more opticalmanipulators. An optical manipulator may generally control a laser beam,such as by directing or positioning the laser beam to remove material,such as rock. In some configurations, an optical manipulator maystrategically guide a laser beam to remove material, such as rock. Forexample, spatial distance from a borehole wall or rock may becontrolled, as well as impact angle. In some configurations, one or moresteerable optical manipulators may control the direction and spatialwidth of the one or more laser beams by one or more reflective mirrorsor crystal reflectors. In other configurations, the optical manipulatorcan be steered by, but steering means not being limited to, anelectro-optic switch, electroactive polymers, galvonometers,piezoelectrics, rotary/linear motors, and/or active-phase control of anarray of sources for electronic beam steering. In at least oneconfiguration, an infrared diode laser or fiber laser optical head maygenerally rotate about a vertical axis to increase aperture contactlength. Various programmable values such as specific energy, specificpower, pulse rate, duration and the like may be implemented as afunction of time. Thus, where to apply energy may be strategicallydetermined, programmed and executed so as to enhance a rate ofpenetration, the efficiency of borehole advancement, and/or laser/rockinteraction. One or more algorithms may be used to control the opticalmanipulator.

The LBHA and optics, in at least one aspect, provide that a beam spotpattern and continuous beam shape may be formed by a refractive,reflective, diffractive or transmissive grating optical element.refractive, reflective, diffractive or transmissive grating opticalelements may be made, but are not limited to being made, of fusedsilica, quartz, ZnSe, Si, GaAs, polished metal, sapphire, and/ordiamond. These may be, but are not limited to being, optically coatedwith the said materials to reduce or enhance the reflectivity.

In accordance with one or more aspects, one or more fiber optic distalfiber ends may be arranged in a pattern. The multiplexed beam shape maycomprise a cross, an x shape, a viewfinder, a rectangle, a hexagon,lines in an array, or a related shape where lines, squares, andcylinders are connected or spaced at different distances.

In accordance with one or more aspects, one or more refractive lenses,diffractive elements, transmissive gratings, and/or reflective lensesmay be added to focus, scan, and/or change the beam spot pattern fromthe beam spots emitting from the fiber optics that are positioned in apattern. One or more refractive lenses, diffractive elements,transmissive gratings, and/or reflective lenses may be added to focus,scan, and/or change the one or more continuous beam shapes from thelight emitted from the beam shaping optics. A collimator may bepositioned after the beam spot shaper lens in the transversing opticalpath plane. The collimator may be an aspheric lens, spherical lenssystem composed of a convex lens, thick convex lens, negative meniscus,and bi-convex lens, gradient refractive lens with an aspheric profileand achromatic doublets. The collimator may be made of the saidmaterials, fused silica, ZnSe, SF glass, or a related material. Thecollimator may be coated to reduce or enhance reflectivity ortransmission. Said optical elements may be cooled by a purging liquid orgas.

In some aspects, the one or more fiber optics with one or more saidoptical elements and beam shaping optics may be steered in thez-direction to keep the focal path constant and rotated by a steppermotor, servo motors, piezoelectric motors, liquid or gas actuator motor,and electro-optics switches. The z-axis may be controlled by the drillstring or mechanical standoff. The steering may be mounted to one ormore stepper rails, gantry's, gimbals, hydraulic line, elevators,pistons, springs. The one or more fiber optics with one or more fiberoptics with one or more said beam shaping optics and one or morecollimator's may be rotated by a stepper motor, servo motors,piezoelectric motors, liquid or gas actuator motor, and electro-opticswitch. The steering may be mounted to one or more stepper rails,gantry's, gimbals, hydraulic line, elevators, pistons, springs.

In some aspects, the fiber optics and said one or more optical elementslenses and beam shaping optics may be encased in a protective opticalhead made of, for example, the materials steel, chrome-moly steel, steelcladded with hard-face materials such as an alloy ofchromium-nickel-cobalt, titanium, tungsten carbide, diamond, sapphire,or other suitable materials known to those in the art which may have atransmissive window cut out to emit the light through the optical head.

In accordance with one or more aspects, a laser source may be coupled toa plurality of optical fiber bundles with the distal end of the fiberarranged to combine fibers together to form bundle pairs, such that thepower density through one fiber bundle pair is within the materialremoval zone and one or more beam spots illuminate the material, such asrock with the bundle pairs arranged in a pattern to remove or displacethe rock formation.

In accordance with one or more aspects, the pattern of the bundle pairsmay be spaced in such a way that the light from the fiber bundle pairsemerge in one or more beam spot patterns that comprise the geometry of arectangular grid, a circle, a hexagon, a cross, a star, a bowtie, atriangle, multiple lines in an array, multiple lines spaced a distanceapart non-linearly, an ellipse, two or more lines at an angle, or arelated shape. The pattern of the bundle pairs may be spaced in such away that the light from the fiber bundles emerge as one or morecontinuous beam shapes that comprise above geometries. A collimator maybe positioned at a said distance in the same plane below the distal endof the fiber bundle pairs. One or more beam shaping optics may bepositioned at a distance in the same plane below the distal end of thefiber bundle pairs. An optical element such as a non-axis-symmetric lensmay be positioned at a said distance in the same plane below the distalend of the fiber bundle pairs. Said optical elements may be positionedat an angle to the rock formation and rotated on an axis.

In accordance with one or more aspects, the distal fiber end made up offiber bundle pairs may be steered in the X,Y,Z, planes and rotationallyusing a stepper motor, servo motors, piezoelectric motors, liquid or gasactuator motor. The distal fiber end may be made up of fiber bundlepairs being steered with a collimator or other optical element, whichcould be an objective, such as a non-axis-symmetric optical element. Thesteering may be mounted to one or more mechanical, hydraulic, orelectro-mechanical element to move the optical element. The distal endof fiber bundle pairs, and optics may be protected as described above.The optical fibers may be single-mode and/or multimode. The opticalfiber bundles may be composed of single-mode and/or multimode fibers.

In some aspects, the optical fibers may be entirely constructed ofglass, hollow core photonic crystals, and/or solid core photoniccrystals. The optical fibers may be jacketed with materials such as,polyimide, acrylate, carbon polyamide, or carbon/dual acrylate. Lightmay be sourced from a diode laser, disk laser, chemical laser, fiberlaser, or fiber optic source is focused by one or more positiverefractive lenses. Further, examples of fibers useful for thetransmission of high powered laser energy over long distance inconjunction with the present invention are provided in patentapplication Ser. No. 12/544,136 filed contemporaneously herewith thedisclosure of which is incorporated herein.

In at least one aspect, the positive refractive lens types may include,a non-axis-symmetric optic such as a plano-convex lens, a biconvex lens,a positive meniscus lens, or a gradient refractive index lens with aplano-convex gradient profile, a biconvex gradient profile, or positivemeniscus gradient profile to focus one or more beams spots to the rockformation. A positive refractive lens may be comprised of the materials,fused silica, sapphire, ZnSe, or diamond. Said refractive lens opticalelements can be steered in the light propagating plane toincrease/decrease the focal length. The light output from the fiberoptic source may originate from a plurality of one or more optical fiberbundle pairs forming a beam shape or beam spot pattern and propagatingthe light to the one or more positive refractive lenses.

It is readily understood in the art that the terms lens and optic(al)elements, as used herein is used in its broadest terms and thus may alsorefer to any optical elements with power, such as reflective,transmissive or refractive elements,

In some aspects, the refractive positive lens may be a microlens. Themicrolens can be steered in the light propagating plane toincrease/decrease the focal length as well as perpendicular to the lightpropagating plane to translate the beam. The microlens may receiveincident light to focus to multiple foci from one or more opticalfibers, optical fiber bundle pairs, fiber lasers, diode lasers; andreceive and send light from one or more collimators, positive refractivelenses, negative refractive lenses, one or more mirrors, diffractive andreflective optical beam expanders, and prisms.

In some aspects, a diffractive optical element beam splitter could beused in conjunction with a refractive lens. The diffractive opticalelement beam splitter may form double beam spots or a pattern of beamspots comprising the shapes and patterns set forth above.

In at least one aspect, the positive refractive lens may focus themultiple beam spots to multiple foci. To remove or displace the rockformation.

In accordance with one or more aspects, a collimator lens may bepositioned in the same plane and in front of a refractive or reflectivediffraction beam splitter to form a beam spot pattern or beam shape;where a beam expander feeds the light into the collimator. The opticalelements may be positioned in the X,Y,Z plane and rotated mechanically.

In accordance with one or more aspects, the laser beam spot to thetransversing mirror may be controlled by a beam expander. The beamexpander may expand the size of the beam and send the beam to acollimator and then to a scanner of two mirrors positioning the laserbeam in the XY, YZ, or XZ axis. A beam expander may expand the size ofthe beam and sends the beam to a collimator, then to a diffractive orreflective optical element, and then to a scanner of two mirrorspositioning the laser beam in the XY, YZ, or XZ axis. A beam expandermay expand the size of the beam and send the beam to a beam splitterattached behind a positive refractive lens, that splits the beam andfocuses is, to a scanner of two mirrors positioning the laser beam inthe XY, YZ, or XZ axis.

In some aspects, the material, such as a rock surface may be imaged by acamera downhole. Data received by the camera may be used to remove ordisplace the rock. Further spectroscopy may be used to determine therock morphology, which information may be used to determine processparameters for removal of material.

In at least one aspect, a gas or liquid purge is employed. The purge gasor liquid may remove or displace the cuttings, rock, or other debrisfrom the borehole. The fluid temperature may be varied to enhance rockremoval, and provide cooling.

In accordance with some embodiments, one or more beam shaping optics maygenerate one or more beam spot lines, circles or squares from the lightemitted by one or more fiber optics or fiber optic bundles. The beamshapes generated by a beam shaper may comprise of being Gaussian, acircular top-hat ring, or line, or rectangle, a polynomial towards theedge ring, or line, or rectangle, a polynomial towards the center ring,or line, or rectangle, a X or Y axis polynomial in a ring, or line, orrectangle, or a asymmetric beam shape beams. One or more beam shapingoptics can be positioned in a pattern to form beam shapes. In anotherembodiment, an optic can be positioned to refocus light from one or morefiber optics or plurality of fiber optics. The optic can be positionedafter the beam spot shaper lens to increase the working distance. Inanother embodiment, diffractive or reflective optical element may bepositioned in front of one or more fiber optics or plurality of fiberoptics. A positive refractive lens may be added after the diffractive orreflective optical element to focus the beam pattern or shape tomultiple foci.

Refractive optics that are useful and may be employed with the presentinvention include but are not limited to: (i) negative lenses, such asbiconcave, plano-concave, negative meniscus, or a gradient refractiveindex with a plano-concave profile, biconvex, or negative meniscus; and,positive lenses such as one or more positive refractive lens profilesmay comprise of biconvex, positive meniscus, or gradient refractiveindex lens with a plano-convex gradient profile, a biconvex gradientprofile, or positive meniscus, such refractive lenses may be flat,cylindrical, spherical, aspherical, or a molded shape. The refractivelens material may be made of any desired material, such as fused silica,ZnSe, sapphire, quartz or diamond.

One or more embodiments may generally include one or more features toprotect the optical element system and/or fiber laser downhole. Inaccordance with one or more embodiments, reflective and refractivelenses may include a cooling system, such as a fluid jet associated withthe optics.

In accordance with one or more embodiments, the one or more lasers,fibers, or plurality of fiber bundles and the optical element systems togenerate one or more beam spots, shape, or patterns from the above lightemitting sources forming an optical head may be protected from downholepressure and environments by being encased in an appropriate material.Such materials may include steel, titanium, diamond, tungsten carbide,composites and the like as well as the other materials provided hereinand known to those skilled in the art. A transmissive window may be madeof a material that can withstand the downhole environment, whileretaining transmissive qualities. One such material may be sapphire orother materials with similar qualities. An optical head may be entirelyencased by sapphire. In at least one embodiment, the optical head may bemade of diamond, tungsten carbide, steel, and titanium other than partwhere the laser beam is emitted.

In accordance with one or more embodiments, the fiber optics forming apattern can send any desired amount of power. In some non-limitingembodiments, fiber optics may send up to 10 kW or more per a fiber. Thefibers may transmit any desired wavelength. In some embodiments, therange of wavelengths the fiber can transmit may preferably be betweenabout 800 nm and 2100 nm. The fiber can be connected by a connector toanother fiber to maintain the proper fixed distance between one fiberand neighboring fibers. For example, fibers can be connected such thatthe beam spot from neighboring optical fibers when irradiating thematerial, such as a rock surface are non-overlapping to the particularoptical fiber. The fiber may have any desired core size. In someembodiments, the core size may range from about 50 microns to 600microns. The fiber can be single mode or multimode. If multimode, thenumerical aperture of some embodiments may range from 0.1 to 0.6. Alower numerical aperture may be preferred for beam quality, and a highernumerical aperture may be easier to transmit higher powers with lowerinterface losses. In some embodiments, a fiber laser emitted light atwavelengths comprised of 1060 nm to 1080 nm, 1530 nm to 1600 nm, 1800 nmto 2100 nm, diode lasers from 400 nm to 1600 nm, CO₂ Laser at 110,600nm, or Nd:YAG Laser emitting at 1064 nm can couple to the opticalfibers. In some embodiments, the fiber can have a low water content. Thefiber can be jacketed, such as with polyimide, acrylate, carbonpolyamide, and carbon/dual acrylate or other material. If requiring hightemperatures, a polyimide or a derivative material may be used tooperate at temperatures over 300 degrees Celsius. By way of example, thefibers may be a fused silica step index fiber, a hollow core fiber, suchas a hollow core photonic crystal, or solid core fiber, such as a solidcore photonic crystal, or combinations of these. In some embodiments,using hollow core photonic crystal fibers at wavelengths of 1500 nm orhigher may minimize absorption losses.

The use of the plurality of optical fibers can be bundled into a numberof configurations to improve power density. The optical fibers forming abundle may range from two fibers at hundreds of watts to kilowatt powersin each fiber to millions of fibers at milliwatts or microwatts ofpower.

In accordance with one or more embodiments, one or more diode lasers canbe sent downhole with an optical element system to form one or more beamspots, shapes, or patterns. In some embodiments, more than one diodelaser may couple to fiber optics, where the fiber optics or a pluralityof fiber optic bundles form a pattern of beam spots irradiating thematerial, such as a rock surface.

Thus, by way of example, an LBHA that may employ the optical assembliesof the present invention or provide a laser beam with energy profiles ofthe present invention is illustrated in FIGS. 13A and B, which arecollectively referred as FIG. 1. Thus, there is provided a LBHA 1340,which has an upper part 1300 and a lower part 1301. The upper part 1300has housing 1318 and the lower part 1301 has housing 1319. The LBHA1340, the upper part 1300, the lower part 1301 and in particular thehousings 1318, 1319 should be constructed of materials and designedstructurally to withstand the extreme conditions of the deep downholeenvironment and protect any of the components that are contained withinthem.

The upper part 1300 may be connected to the lower end of the coiledtubing, drill pipe, or other means to lower and retrieve the LBHA 1340from the borehole. Further, it may be connected to stabilizers, drillcollars, or other types of downhole assemblies (not shown in thefigure), which in turn are connected to the lower end of the coiledtubing, drill pipe, or other means to lower and retrieve the LBHA 1340from the borehole. The upper part 1300 further contains, is connect to,or otherwise optically associated with the means 1302 that transmittedthe high power laser beam down the borehole so that the beam exits thelower end 1303 of the means 1302 and ultimately exist the LBHA 1340 tostrike the intended surface of the borehole. The beam path of the highpower laser beam is shown by arrow 1315. In FIG. 1 the means 1302 isshown as a single optical fiber. The upper part 1300 may also have airamplification nozzles 1305 that discharge the drilling fluid, forexample N₂, to among other things assist in the removal of cuttings upthe borehole.

The upper part 1300 further is attached to, connected to or otherwiseassociated with a means to provide rotational movement 1310. Such means,for example, would be a downhole motor, an electric motor or a mudmotor. The motor may be connected by way of an axle, drive shaft, drivetrain, gear, or other such means to transfer rotational motion 1311, tothe lower part 1301 of the LBHA 1340. It is understood, as shown in thedrawings for purposes of illustrating the underlying apparatus, that ahousing or protective cowling may be placed over the drive means orotherwise associated with it and the motor to protect it form debris andharsh downhole conditions. In this manner the motor would enable thelower part 1301 of the LBHA 1340 to rotate. An example of a mud motor isthe CAVO 1.7″ diameter mud motor. This motor is about 7 ft long and hasthe following specifications: 7 horsepower @ 110 ft-lbs full torque;motor speed 0-700 rpm; motor can run on mud, air, N₂, mist, or foam; 180SCFM, 500-800 psig drop; support equipment extends length to 12 ft; 10:1gear ratio provides 0-70 rpm capability; and has the capability torotate the lower part 1301 of the LBHA through potential stallconditions.

The upper part 1300 of the LBHA 1340 is joined to the lower part 1301with a sealed chamber 1304 that is transparent to the laser beam andforms a pupil plane 1320 to permit unobstructed transmission of thelaser beam to the beam shaping optics 1306 in the lower part 1301. Thelower part 1301 is designed to rotate. The sealed chamber 1304 is influid communication with the lower chamber 1301 through port 1314. Port1314 may be a one way valve that permits clean transmissive fluid andpreferably gas to flow from the upper part 1300 to the lower part 1301,but does not permit reverse flow, or if may be another type of pressureand/or flow regulating value that meets the particular requirements ofdesired flow and distribution of fluid in the downhole environment.Thus, for example there is provided in FIG. 1 a first fluid flow path,shown by arrows 1316, and a second fluid flow path, shown by arrows1317. In the example of FIG. 13 the second fluid flow path is a laminarflow, however, other non-laminar flows and low turbulent flows arepermissible.

The lower part 1301 has a means for receiving rotational force from themotor 1310, which in the example of the figure is a gear 1312 locatedaround the lower part housing 1319 and a drive gear 1313 located at thelower end of the axle 1311. Other means for transferring rotationalpower may be employed or the motor may be positioned directly on thelower part. It being understood that an equivalent apparatus may beemployed which provide for the rotation of the portion of the LBHA tofacilitate rotation or movement of the laser beam spot while that thesame time not providing undue rotation, or twisting forces, to theoptical fiber or other means transmitting the high power laser beam downthe hole to the LBHA. In his way laser beam spot can be rotated aroundthe bottom of the borehole. The lower part 1301 has a laminar flowoutlet 1307 for the fluid to exit the LBHA 1300, and two hardenedrollers 1308, 1309 at its lower end.

The two hardened rollers may be made of a stainless steel or a steelwith a hard face coating such as tungsten carbide,chromium-cobalt-nickel alloy, or other similar materials. They may alsocontain a means for mechanically cutting rock that has been thermallydegraded by the laser. They may range in length from about 1 in to about4 inches and preferably are about 2-3 inches and may be as large as orlarger than 6 inches. (Length as used herein refers to the longestdimenstion of the roller.) Moreover in LBHAs for drilling largerdiameter boreholes they may be in the range of 6 to 10-20 to 30 inchesin diameter.

Thus, FIG. 13 provides for a high power laser beam path 1315 that entersthe LBHA 1340, travels through beam spot shaping optics 1306, and thenexits the LBHA to strike its intended target on the surface of aborehole. Further, although it is not required, the beam spot shapingoptics may also provide a rotational element to the spot, and if so,would be considered to be beam rotational and shaping spot optics.

In use the high energy laser beam, for example greater than 15 kW, wouldenter the LBHA 1300, travel down fiber 1302, exit the end of the fiber1303 and travel through the sealed chamber 1304 and pupil plane 1320into the optics 1306, where it would be shaped and focused into a spot,the optics 1306 would further rotate the spot. The laser beam would thenilluminate, in a potentially rotating manner, the bottom of the boreholespalling, chipping melting and/or vaporizing the rock and earthilluminated and thus advance the borehole. The lower part would berotating and this rotation would further cause the rollers 1308, 1309 tophysically dislodge any material that was effected by the laser orotherwise sufficiently fixed to not be able to be removed by the flow ofthe drilling fluid alone.

The cuttings would be cleared from the laser path by the flow of thefluid along the path 1317, as well as, by the action of the rollers2008, 2009 and the cuttings would then be carried up the borehole by theaction of the drilling fluid from the air amplifiers 1305, as well as,the laminar flow opening 1307.

It is understood that the configuration of the LBHA is FIG. 13 is by wayof example and that other configurations of its components are availableto accomplish the same results. Thus, the motor may be located in thelower part rather than the upper part, the motor may be located in theupper part but only turn the optics in the lower part and not thehousing. The optics may further be located in both the upper and lowerparts, which the optics for rotation being positioned in that part whichrotates. The motor may be located in the lower part but only rotate theoptics and the rollers. In this later configuration the upper and lowerparts could be the same, i.e., there would only be one part to the LBHA.Thus, for example the inner portion of the LBHA may rotate while theouter portion is stationary or vice versa, similarly the top and/orbottom portions may rotate or various combinations of rotating andnon-rotating components may be employed, to provide for a means for thelaser beam spot to be moved around the bottom of the borehole.

In general, and by way of further example, the LBHA may comprise ahousing, which may by way of example, be made up of sub-housings. Thesesub-housings may be integral, they may be separable, they may beremovably fixedly connected, they may be rotatable, or there may be anycombination of one or more of these types of relationships between thesub-housings. The LBHA may be connected to the lower end of the coiledtubing, drill pipe, or other means to lower and retrieve the LBHA fromthe borehole. Further, it may be connected to stabilizers, drillcollars, or other types of downhole assemblies, which in turn areconnected to the lower end of the coiled tubing, drill pipe, or othermeans to lower and retrieve the bottom hole assembly from the borehole.The LBHA has associated therewith a means that transmitted the highpower energy from down the borehole.

The LBHA may also have associated with, or in, it means to handle anddeliver drilling fluids. These means may be associated with some or allof the sub-housings. There are further provided mechanical scrapingmeans, e.g. a PDC bit, to remove and/or direct material in the borehole,although other types of known bits and/or mechanical drilling heads byalso be employed in conjunction with the laser beam. These scrapers orbits may be mechanically interacted with the surface or parts of theborehole to loosen, remove, scrap or manipulate such borehole materialas needed. These scrapers may be from less than about 1 inch to about 20inches or more in length. These types of mechanical means which may becrushing, cutting, gouging scraping, grinding, pulverizing, and shearingtools, or other tools used for mechanical removal of material from aborehole, may be employed in conjunction with or association with aLBHA. As used herein the “length” of such tools refers to its longestdimension. In use the high energy laser beam, for example greater than15 kW, would travel down the fibers through optics and then out thelower end of the LBHA to illuminate the intended part of the borehole,or structure contained therein, spalling, chipping, melting and/orvaporizing the material so illuminated and thus advance the borehole orotherwise facilitating the removal of the material so illuminated.

The optics 1306 should be selected to avoid or at least minimize theloss of power as the laser beam travels through them. The optics shouldfurther be designed to handle the extreme conditions present in thedownhole environment, at least to the extent that those conditions arenot mitigated by the housing 1319. The optics may provide laser beamspots of differing power distributions and shapes as set forth hereinabove. The optics may further provide a single spot or multiple spots asset forth herein above. Further examples and teaching of LBHAs aredisclosed in greater detail in co-pending U.S. patent application Ser.No. 12/544,038, and Ser. No. 12/543,968 filed contemporaneouslyherewith, the disclosures of which are incorporate herein by referencein their entirety.

In general, the output at the end of the fiber cable may consist of oneor many optical fibers. The beam shape at the rock once determined canbe created by either reimaging the fiber (bundle), collimating the fiber(bundle) and then transforming it to the Fourier plane to provide ahomogeneous illumination of the rock surface, or after collimation adiffractive optic, micro-optic or axicon array could be used to createthe beam patterned desired. This beam pattern can be applied directly tothe rock surface or reimaged, or Fourier transformed to the rock surfaceto achieve the desired pattern. The processing head may include adichroic splitter to allow the integration of a camera or a fiber opticimaging system monitoring system into the processing head to allowprogress to be monitored and problem to be diagnosed.

Drilling may be conducted in a dry environment or a wet environment. Animportant factor is that the path from the laser to the rock surfaceshould be kept as clear as practical of debris and dust particles orother material that would interfere with the delivery of the laser beamto the rock surface. The use of high brightness lasers provides anotheradvantage at the process head, where long standoff distances from thelast optic to the work piece are important to keeping the high pressureoptical window clean and intact through the drilling process. The beamcan either be positioned statically or moved mechanically,opto-mechanically, electro-optically, electromechanically, or anycombination of the above to illuminate the earth region of interest.

Thus, in general, and by way of example, there is provided in FIG. 14 ahigh efficiency laser drilling system, including an LBHA, which may usethe optics of the present invention and which may employ the laser shotpatterns, and energy deposition profiles of the present invention. Suchsystems are disclosed in greater detail in co-pending U.S. patentapplication Ser. No. 12/544,136, filed contemporaneously herewith, thedisclosure of which is incorporate herein by reference in its entirety.

Thus, in general, and by way of example, there is provided in FIG. 14 ahigh efficiency laser drilling system 1400 for creating a borehole 1401in the earth 1402. As used herein the term “earth” should be given itsbroadest possible meaning (unless expressly stated otherwise) and wouldinclude, without limitation, the ground, all natural materials, such asrocks, and artificial materials, such as concrete, that are or may befound in the ground, including without limitation rock layer formations,such as, granite, basalt, sandstone, dolomite, sand, salt, limestone,rhyolite, quartzite and shale rock.

FIG. 14 provides a cut away perspective view showing the surface of theearth 1430 and a cut away of the earth below the surface 1402. Ingeneral and by way of example, there is provided a source of electricalpower 1403, which provides electrical power by cables 1404 and 1405 to alaser 1406 and a chiller 1407 for the laser 1406. The laser provides alaser beam, i.e., laser energy, that can be conveyed by a laser beamtransmission means 1408 to a spool of coiled tubing 1409. A source offluid 1410 is provided. The fluid is conveyed by fluid conveyance means1411 to the spool of coiled tubing 1409.

The spool of coiled tubing 1409 is rotated to advance and retract thecoiled tubing 1412. Thus, the laser beam transmission means 1408 and thefluid conveyance means 1411 are attached to the spool of coiled tubing1409 by means of rotating coupling means 1413. The coiled tubing 1412contains a means to transmit the laser beam along the entire length ofthe coiled tubing, i.e., “long distance high power laser beamtransmission means,” to the bottom hole assembly, 1414. The coiledtubing 1412 also contains a means to convey the fluid along the entirelength of the coiled tubing 1412 to the bottom hole assembly 1414.

Additionally, there is provided a support structure 1415, which forexample could be derrick, crane, mast, tripod, or other similar type ofstructure. The support structure holds an injector 1416, to facilitatemovement of the coiled tubing 1412 in the borehole 1401. As the boreholeis advance to greater depths from the surface 1430, the use of adiverter 1417, a blow out preventer (BOP) 1418, and a fluid and/orcutting handling system 1419 may become necessary. The coiled tubing1412 is passed from the injector 1416 through the diverter 1417, the BOP1418, a wellhead 1420 and into the borehole 1401.

The fluid is conveyed to the bottom 1421 of the borehole 1401. At thatpoint the fluid exits at or near the bottom hole assembly 1414 and isused, among other things, to carry the cuttings, which are created fromadvancing a borehole, back up and out of the borehole. Thus, thediverter 1417 directs the fluid as it returns carrying the cuttings tothe fluid and/or cuttings handling system 1419 through connector 1422.This handling system 1419 is intended to prevent waste products fromescaping into the environment and either vents the fluid to the air, ifpermissible environmentally and economically, as would be the case ifthe fluid was nitrogen, returns the cleaned fluid to the source of fluid1410, or otherwise contains the used fluid for later treatment and/ordisposal.

The BOP 1418 serves to provide multiple levels of emergency shut offand/or containment of the borehole should a high-pressure event occur inthe borehole, such as a potential blow-out of the well. The BOP isaffixed to the wellhead 1420. The wellhead in turn may be attached tocasing. For the purposes of simplification the structural components ofa borehole such as casing, hangers, and cement are not shown. It isunderstood that these components may be used and will vary based uponthe depth, type, and geology of the borehole, as well as, other factors.

The downhole end 1423 of the coiled tubing 1412 is connect to the bottomhole assembly 1414. The bottom hole assemble 1414 contains optics fordelivering the laser beam 1424 to its intended target, in the case ofFIG. 4, the bottom 1421 of the borehole 1401. The bottom hole assemble1414, for example, also contains means for delivering the fluid.

Thus, in general this system operates to create and/or advance aborehole by having the laser create laser energy in the form of a laserbeam. The laser beam is then transmitted from the laser through thespool and into the coiled tubing. At which point, the laser beam is thentransmitted to the bottom hole assembly where it is directed toward thesurfaces of the earth and/or borehole. Upon contacting the surface ofthe earth and/or borehole the laser beam has sufficient power to cut, orotherwise effect, the rock and earth creating and/or advancing theborehole. The laser beam at the point of contact has sufficient powerand is directed to the rock and earth in such a manner that it iscapable of borehole creation that is comparable to or superior to aconventional mechanical drilling operation. Depending upon the type ofearth and rock and the properties of the laser beam this cutting occursthrough spalling, thermal dissociation, melting, vaporization andcombinations of these phenomena.

Although not being bound by the present theory, it is presently believedthat the laser material interaction entails the interaction of the laserand a fluid or media to clear the area of laser illumination. Thus thelaser illumination creates a surface event and the fluid impinging onthe surface rapidly transports the debris, i.e. cuttings and waste, outof the illumination region. The fluid is further believed to remove heateither on the macro or micro scale from the area of illumination, thearea of post-illumination, as well as the borehole, or other media beingcut, such as in the case of perforation.

The fluid then carries the cuttings up and out of the borehole. As theborehole is advanced the coiled tubing is unspooled and lowered furtherinto the borehole. In this way the appropriate distance between thebottom hole assembly and the bottom of the borehole can be maintained.If the bottom hole assembly needs to be removed from the borehole, forexample to case the well, the spool is wound up, resulting in the coiledtubing being pulled from the borehole. Additionally, the laser beam maybe directed by the bottom hole assembly or other laser directing toolthat is placed down the borehole to perform operations such asperforating, controlled perforating, cutting of casing, and removal ofplugs. This system may be mounted on readily mobile trailers or trucks,because its size and weight are substantially less than conventionalmechanical rigs.

There is provided by way of examples illustrative and simplified plansof potential drilling scenarios using the laser drilling systems andapparatus of the present invention.

Drilling Plan Example 1

Drilling type/Laser Depth Rock type power down hole Drill 17½ Surface-Sand and Conventional inch hole 3000 ft shale mechanical drilling Run13⅜ Length inch casing 3000 ft Drill 12¼ 3000 ft- basalt 40 kW inch hole8,000 ft (minimum) Run 9⅝ Length inch casing 8,000 ft Drill 8½ 8,000 ft-limestone Conventional inch hole 11,000 ft mechanical drilling Run 7inch Length casing 11,000 ft Drill 6¼ 11,000 ft- Sand stone Conventionalinch hole 14,000 ft mechanical drilling Run 5 inch Length liner 3000 ft

Drilling Plan Example 2

Drilling type/Laser Depth Rock type power down hole Drill 17½ Surface-Sand and Conventional inch hole 500 ft shale mechanical drilling Run 13⅜Length casing 500 ft Drill 12¼ 500 ft- granite 40 kW hole 4,000 ft(minimum) Run 9⅝ Length inch casing 4,000 ft Drill 8½ 4,000 ft- basalt20 kW inch hole 11,000 ft (mimimum) Run 7 inch Length casing 11,000 ftDrill 6¼ 11,000 ft- Sand stone Conventional inch hole 14,000 ftmechanical drilling Run 5 inch Length liner 3000 ft

In accordance with one or more aspects, a method for laser drillingusing an optical pattern to chip rock formations is disclosed. Themethod may comprise irradiating the rock to spall, melt, or vaporizewith one or more lasing beam spots, beam spot patterns and beam shapesat non-overlapping distances and timing patterns to induce overlappingthermal rock fractures that cause rock chipping of rock fragments.Single or multiple beam spots and beam patterns and shapes may be formedby refractive and reflective optics or fiber optics. The opticalpattern, the pattern's timing, and spatial distance betweennon-overlapping beam spots and beam shapes may be controlled by the rocktype thermal absorption at specific wavelength, relaxation time toposition the optics, and interference from rock removal.

In some aspects, the lasing beam spot's power is either not reduced,reduced moderately, or fully during relaxation time when repositioningthe beam spot on the rock surface. To chip the rock formation, twolasing beam spots may scan the rock surface and be separated by a fixedposition of less than 2″ and non-overlapping in some aspects. Each ofthe two beam spots may have a beam spot area in the range between 0.1cm² and 25 cm². The relaxation times when moving the two lasing beamspots to their next subsequent lasing locations on the rock surface mayrange between 0.05 ms and 2 s. When moving the two lasing beam spots totheir next position, their power may either be not reduced, reducedmoderately, or fully during relaxation time.

In accordance with one or more aspects, a beam spot pattern may comprisethree or more beam spots in a grid pattern, a rectangular grid pattern,a hexagonal grid pattern, lines in an array pattern, a circular pattern,a triangular grid pattern, a cross grid pattern, a star grid pattern, aswivel grid pattern, a viewfinder grid pattern or a relatedgeometrically shaped pattern. In some aspects, each lasing beam spot inthe beam spot pattern has an area in the range of 0.1 cm² and 25 cm². Tochip the rock formation all the neighboring lasing beam spots to eachlasing beam spot in the beam spot pattern may be less than a fixedposition of 2″ and non-overlapping in one or more aspects.

In some aspects, more than one beam spot pattern to chip the rocksurface may be used. The relaxation times when positioning one or morebeam spot patterns to their next subsequent lasing location may rangebetween 0.05 ms and 2 s. The power of one or more beam spot patterns mayeither be not reduced, reduced moderately, or fully during relaxationtime. A beam shape may be a continuous optical beam spot forming ageometrical shape that comprises of, a cross shape, hexagonal shape, aspiral shape, a circular shape, a triangular shape, a star shape, a lineshape, a rectangular shape, or a related continuous beam spot shape.

In some aspects, positioning one line either linear or non-linear to oneor more neighboring lines either linear or non-linear at a fixeddistance less than 2″ and non-overlapping may be used to chip the rockformation. Lasing the rock surface with two or more beam shapes may beused to chip the rock formation. The relaxation times when moving theone or more beam spot shapes to their next subsequent lasing locationmay range between 0.05 ms and 2 s.

In accordance with one or more aspects, the one or more continuous beamshapes powers are either not reduced, reduced moderately, or fullyduring relaxation time. The rock surface may be irradiated by one ormore lasing beam spot patterns together with one or more beam spotshapes, or one or two beam spots with one or more beam spot patterns. Insome aspects, the maximum diameter and circumference of one or more beamshapes and beam spot patterns is the size of the borehole being chippedwhen drilling the rock formation to well completion.

In accordance with one or more aspects, rock fractures may be created topromote chipping away of rock segments for efficient borehole drilling.In some aspects, beam spots, shapes, and patterns may be used to createthe rock fractures so as to enable multiple rock segments to be chippedaway. The rock fractures may be strategically patterned. In at leastsome aspects, drilling rock formations may comprise applying one or morenon-overlapping beam spots, shapes, or patterns to create the rockfractures. Selection of one or more beam spots, shapes, and patterns maygenerally be based on the intended application or desired operatingparameters. Average power, specific power, timing pattern, beam spotsize, exposure time, associated specific energy, and optical generatorelements may be considerations when selecting one or more beam spots, ashape, or a pattern. The material to be drilled, such as rock formationtype, may also influence the one or more beam spot, a shape, or apattern selected to chip the rock formation. For example, shale willabsorb light and convert to heat at different rates than sandstone.

In accordance with one or more aspects, rock may be patterned with oneor more beam spots. In at least one embodiment, beam spots may beconsidered one or more beam spots moving from one location to the nextsubsequent location lasing the rock surface in a timing pattern. Beamspots may be spaced apart at any desired distance. In some non-limitingaspects, the fixed position between one beam spot and neighboring beamspots may be non-overlapping. In at least one non-limiting embodiment,the distance between neighboring beam spots may be less than 2″.

In accordance with one or more aspects, rock may be patterned with oneor more beam shapes. In some aspects, beam shapes may be continuousoptical shapes forming one or more geometric patterns. A pattern maycomprise the geometric shapes of a line, cross, viewfinder, swivel,star, rectangle, hexagon, circular, ellipse, squiggly line, or any otherdesired shape or pattern. Elements of a beam shape may be spaced apartat any desired distance. In some non-limiting aspects, the fixedposition between each line linear or non-linear and the neighboringlines linear or non-linear are in a fixed position may be less than 2″and non-overlapping.

In accordance with one or more aspects, rock may be patterned with abeam pattern. Beam patterns may comprise a grid or array of beam spotsthat may comprise the geometric patterns of line, cross, viewfinder,swivel, star, rectangle, hexagon, circular, ellipse, squiggly line. Beamspots of a beam pattern may be spaced apart at any desired distance. Insome non-limiting aspects, the fixed position between each beam spot andthe neighboring beam spots in the beam spot pattern may be less than 2″and non-overlapping.

In accordance with one or more aspects, the beam spot being scanned mayhave any desired area. For example, in some non-limiting aspects thearea may be in a range between about 0.1 cm² and about 25 cm². The beamline, either linear or non-linear, may have any desired specificdiameter and any specific and predetermined power distribution. Forexample, the specific diameter of some non-limiting aspects may be in arange between about 0.05 cm² and about 25 cm². In some non-limitingaspects, the maximum length of a line, either linear or non-linear, maygenerally be the diameter of a borehole to be drilled. Any desiredwavelength may be used. In some aspects, for example, the wavelength ofone or more beam spots, a shape, or pattern, may range from 800 nm to2000 nm. Combinations of one or more beam spots, shapes, and patternsare possible and may be implemented.

In accordance with one or more aspects, the timing patterns and locationto chip the rock may vary based on known rock chipping speeds and/orrock removal systems. In one embodiment, relaxation scanning times whenpositioning one or more beam spot patterns to their next subsequentlasing location may range between 0.05 ms and 2 s. In anotherembodiment, a camera using fiber optics or spectroscopy techniques canimage the rock height to determine the peak rock areas to be chipped.The timing pattern can be calibrated to then chip the highest peaks ofthe rock surface to lowest or peaks above a defined height using signalprocessing, software recognition, and numeric control to the opticallens system. In another embodiment, timing patterns can be defined by arock removal system. For example, if the fluid sweeps from the left sidethe rock formation to the right side to clear the optical head and raisethe cuttings, the timing should be chipping the rock from left to rightto avoid rock removal interference to the one or more beam spots, shape,or pattern lasing the rock formation or vice-a-versa. For anotherexample, if the rocks are cleared by a jet nozzle of a gas or liquid,the rock at the center should be chipped first and the direction of rockchipping should move then away from the center. In some aspects, thespeed of rock removal will define the relaxation times.

In accordance with one or more aspects, the rock surface may be affectedby the gas or fluids used to clear the head and raise the cuttingsdownhole. In one embodiment, heat from the optical elements and lossesfrom the fiber optics downhole or diode laser can be used to increasethe temperature of the borehole. This could lower the requiredtemperature to induce spallation making it easier to spall rocks. Inanother embodiment, a liquid may saturate the chipping location, in thissituation the liquid would be turned to steam and expand rapidly, thisrapid expansion would thus create thermal shocks improving the growth offractures in the rock. In another embodiment, an organic, volatilecomponents, minerals or other materials subject to rapid anddifferential heating from the laser energy, may expand rapidly, thisrapid expansion would thus create thermal shocks improving the growth offractures in the rock. In another embodiment, the fluids of higher indexof refraction may be sandwiched between two streams of liquid with lowerindex of refraction. The fluids used to clear the rock can act as awavelength to guide the light. A gas may be used with a particular indexof refraction lower than a fluid or another gas.

By way of example and to further illustrate the teachings of the presentinventions, the thermal shocks can range from lasing powers between oneand another beam spot, shape, or pattern. In some non-limiting aspects,the thermal shocks may reach 10 kW/cm² of continuous lasing powerdensity. In some non-limiting aspects, the thermal shocks may reach upto 10 MW/cm² of pulsed lasing power density, for instance, at 10nanoseconds per pulse. In some aspects, two or more beam spots, shapes,and patterns may have different power levels to thermally shock therock. In this way, a temperature gradient may be formed between lasingof the rock surface.

By way of example and to further demonstrate the present teachings ofthe inventions, there are provided examples of optical heads, i.e.,optical assemblies, and beam shot patterns, i.e., illumination patterns,that may be utilized with, as a part of, or provided by an LBHA. FIG. 15illustrates chipping a rock formation using a lasing beam shape pattern.An optical beam 1501 shape lasing pattern forming a checkerboard oflines 1502 irradiates the rock surface 1503 of a rock 1504. The distancebetween the beam spots shapes are non-overlapping because stress andheat absorption cause natural rock fractures to overlap inducingchipping of rock segments. These rock segments 1505 may peel or explodefrom the rock formation.

By way of example and to further demonstrate the present teachings, FIG.16 illustrates removing rock segments by sweeping liquid or gas flow1601 when chipping a rock formation 1602. The rock segments are chippedby a pattern 1606 of non-overlapping beam spot shaped lines 1603, 1604,1605. The optical head 1607, optically associated with an optical fiberbundle, the optical head 1607 having an optical element systemirradiates the rock surface 1608. A sweeping from left to right with gasor liquid flow 1601 raises the rock fragments 1609 chipped by thethermal shocks to the surface.

By way of example and to further demonstrate the present teachings, FIG.17 illustrates removing rock segments by liquid or gas flow directedfrom the optical head when chipping a rock formation 1701. The rocksegments are chipped by a pattern 1702 of non-overlapping beam spotshaped lines 1703, 1704, 1705. The optical head 1707 with an opticalelement system irradiates the rock surface 1708. Rock segment debris1709 is swept from a nozzle 1715 flowing a gas or liquid 1711 from thecenter of the rock formation and away. The optical head 1707 is shownattached to a rotating motor 1720 and fiber optics 1724 spaced in apattern. The optical head also has rails 1728 for z-axis motion ifnecessary to focus. The optical refractive and reflective opticalelements form the beam path.

By way of example and to further demonstrate the present teachings, FIG.18 illustrates optical mirrors scanning a lasing beam spot or shape tochip a rock formation in the XY-plane. Thus, there is shown, withrespect to a casing 1823 in a borehole, a first motor of rotating 1801,a plurality of fiber optics in a pattern 1803, a gimbal 1805, a secondrotational motor 1807 and a third rotational motor 1809. The secondrotational motor 1807 having a stepper motor 1811 and a mirror 1815associated therewith. The third rotational motor 1809 having a steppermotor 1813 and a mirror 1817 associated therewith. The optical elements1819 optically associated with optical fibers 1803 and capable ofproviding laser beam along optical path 1821. As the gimbal rotatesaround the z-axis and repositions the mirrors in the XY-plane. Themirrors are attached to a stepper motor to rotate stepper motors andmirrors in the XY-plane. In this embodiment, fiber optics are spaced ina pattern forming three beam spots manipulated by optical elements thatscan the rock formation a distance apart and non-overlapping to causerock chipping. Other fiber optic patterns, shapes, or a diode laser canbe used.

By way of example and to further demonstrate the present teachings, FIG.19 illustrates using a beam splitter lens to form multiple beam foci tochip a rock formation. There is shown fibers 1901 in a pattern, a rail1905 for providing z direction movement shown by arrow 1903, a fiberconnector 1907, an optical head 1909, having a beam expander 1919, whichcomprises a DOE/ROE 1915, a positive lens 1917, a collimator 1913, abeam expander 1911. This assembly is capable of delivering one or morelaser beams, as spots 1931 in a pattern, along optical paths 1929 to arock formation 1923 having a surface 1925. Fiber optics are spaced adistance apart in a pattern. An optical element system composed of abeam expander and collimator feed a diffractive optical element attachedto a positive lens to focus multiple beam spots to multiple foci. Thedistance between beam spots are non-overlapping and will cause chipping.In this figure, rails move in the z-axis to focus the optical path. Thefibers are connected by a connector. Also, an optical element can beattached to each fiber optic as shown in this figure to more than onefiber optics.

By way of example and to further demonstrate the present teachings, FIG.20 illustrates using a beam spot shaper lens to shape a pattern to chipa rock formation. There is provided an array of optical fibers 2001, anoptical head 2009. The optical head having a rail 2003 for facilitatingmovement in the z direction, shown by arrow 2005, a fiber connector2007, an optics assembly 2001 for shaping the laser beam that istransmitted by the fibers 2001. The optical head capable of transmittinga laser beam along optical path 2013 to illuminate a surface 2019 with alaser beam shot pattern 2021 that has separate, but intersection linesin a grid like pattern. Fiber optics are spaced a distance apart in apattern connected by a connector. The fiber optics emit a beam spot to abeam spot shaper lens attached to the fiber optic. The beam spot shaperlens forms a line in this figure overlapping to form a tick-tack-toelaser pattern on the rock surface. The optical fiber bundle wires areattached to rails moving in the z-axis to focus the beam spots.

By way of example and to further demonstrate the present teachings, FIG.21 illustrates using a F-theta objective to focus a laser beam patternto a rock formation to cause chipping. There is provided an optical head2101, a first motor for providing rotation 2103, a plurality of opticalfibers 2105, a connector 2107, which positions the fibers in apredetermined pattern 2109. The laser beam exits the fibers and travelsalong optical path 2111 through F-Theta optics 2115 and illuminates rocksurface 2113 in shot pattern 2110. There is further shown rails 2117 forproviding z-direction movement. Fiber optics connected by connectors ina pattern are rotated in the z-axis by a gimbal attached to the opticalcasing head. The beam path is then refocused by an F-theta objective tothe rock formation. The beam spots are a distance apart andnon-overlapping to induce rock chipping in the rock formation. A rail isattached to the optical fibers and F-theta objective moving in thez-axis to focus the beam spot size.

It is understood that the rails in these examples for providingz-direction movement are provided by way of illustration and thatz-direction movement, i.e. movement toward or away from the bottom ofthe borehole may be obtained by other means, for example winding andunwinding the spool or raising and lowering the drill string that isused to advance the LBHA into or remove the LBHA from the borehole.

By way of example and to further demonstrate the present teachings, FIG.22 illustrates mechanical control of fiber optics attached to beamshaping optics to cause rock chipping. There is provided a bundle of aplurality of fibers 2201 first motor 2205 for providing rotationalmovement a power cable 2203, an optical head 2206, and rails 2207. Thereis further provided a second motor 2209, a fiber connector 2213 and alens 2221 for each fiber to shape the beam. The laser beams exit thefibers and travel along optical paths 2215 and illumate the rock surface2219 in a plurality of individual line shaped shot patterns 2217. Fiberoptics are connected by connectors in a pattern and are attached to arotating gimbal motor around the z-axis. Rails are attached to the motormoving in the z-axis. The rails are structurally attached to the opticalhead casing and a support rail. A power cable powers the motors. In thisfigure, the fiber optics emit a beam spot to a beam spot shaper lensforming three non-overlapping lines to the rock formation to induce rockchipping.

By way of example and to further demonstrate the present teachings, FIG.23 illustrates using a plurality of fiber optics to form a beam shapeline. There is provided an optical assembly 2311 having a source oflaser energy 2301, a power cable 2303, a first rotational motor 2305,which is mounted as a gimbal, a second motor 2307, and rails 2317 forz-direction movement. There is also provided a plurality of fiberbundles 2321, with each bundle containing a plurality of individualfibers 2323. The bundles 2321 are held in a predetermined position byconnector 2325. Each bundle 2321 is optically associated with a beamshaping optics 2309. The laser beams exit the beam shaping optics 2309and travel along optical path 2315 to illuminate surface 2319. Themotors 2307, 2305 provide for the ability to move the plurality of beamspots in a plurality of predetermined and desired patterns on thesurface 2319, which may be the surface the borehole, such as the bottomsurface, side surface, or casing in the borehole. A plurality of fiberoptics are connected by connectors in a pattern and are attached to arotating gimbal motor around the z-axis. Rails are attached to the motormoving in the z-axis. The rails are structurally attached to the opticalhead casing and a support rail. A power cable powers the motors. In thisfigure, the plurality of fiber optics emits a beam spot to a beam spotshaper lens forming three lines that are non-overlapping to the rockformation. The beam shapes induce rock chipping.

By way of example and to further demonstrate the present teachings, FIG.24 illustrates using a plurality of fiber optics to form multiple beamspot foci being rotated on an axis. There is provided a laser source2401, a first motor 2403, which is gimbal mounted, a second motor 2405and a means for z-direction movement 2407. There is further provided aplurality of fiber bundles 2413 and a connector 2409 for positioning theplurality of bundles 2413, the laser beam exits the fibers andilluminates a surface in a diverging and crossing laser shot pattern.The fiber optics are connected by connectors at an angle being rotatedby a motor attached to a gimbal that is attached to a second motormoving in the z-axis on rails. The motors receive power by a powercable. The rails are attached to the optical casing head and supportrail beam. In this figure, a collimator sends the beam spot originatingfrom the plurality of optical fibers to a beam splitter. The beamsplitter is a diffractive optical element that is attached to positiverefractive lens. The beam splitter forms multiple beam spot foci to therock formation at non-overlapping distances to chip the rock formation.The foci is repositioned in the z-axis by the rails.

By way of example and to further demonstrate the present teachings, FIG.25 illustrates scanning the rock surface with a beam pattern and XYscanner system. There is provided an optical path 2501 for a laser beam,a scanner 2503, a diffractive optics 2505 and a collimator optics 2507.An optical fiber emits a beam spot that is expanded by a beam expanderunit and focused by a collimator to a refractive optical element. Therefractive optical element is positioned in front of an XY scanner unitto form a beam spot pattern or shape. The XY scanner composed of twomirrors controlled by galvanometer mirrors 2509 irradiate the rocksurface 2513 to induce chipping.

The novel and innovative apparatus of the present invention, as setforth herein, may be used with conventional drilling rigs and apparatusfor drilling, completion and related and associated operations. Theapparatus and methods of the present invention may be used with drillingrigs and equipment such as in exploration and field developmentactivities. Thus, they may be used with, by way of example and withoutlimitation, land based rigs, mobile land based rigs, fixed tower rigs,barge rigs, drill ships, jack-up platforms, and semi-submersible rigs.They may be used in operations for advancing the well bore, finishingthe well bore and work over activities, including perforating theproduction casing. They may further be used in window cutting and pipecutting and in any application where the delivery of the laser beam to alocation, apparatus or component that is located deep in the well boremay be beneficial or useful.

From the foregoing description, one skilled in the art can readilyascertain the essential characteristics of this invention, and withoutdeparting from the spirit and scope thereof, can make various changesand/or modifications of the invention to adapt it to various usages andconditions.

1-54. (canceled)
 55. A system for forming a well in the earthcomprising: a. a high power laser source; b. a bottom hole assemblycomprising a housing, the housing defining a cavity; c. a fiberoptically connecting the laser source with the bottom hole assembly,such that a laser beam from the laser source is transmitted to thebottom hole assembly; d. a means for providing the laser beam to astrike of a borehole; e. a beam power deposition optic having a propertyof changing an energy distribution profile within the laser beam; and,f. the cavity at least partially containing: i. the means for providingthe laser beam to the surface of the borehole; and, ii. the providingmeans comprising the beam power deposition optic; g. wherein, the laserbeam as delivered from the bottom hole assembly illuminates the surfaceof the borehole with a substantially even energy deposition profile onthe surface.
 56. The system of claim 55, wherein the laser sourceprovides a plurality of laser beams to the fiber.
 57. The system ofclaim 55, wherein the laser beam has a substantially uniform profile atthe fiber bottom hole assembly connection.
 58. The system of claim 55,wherein the laser beam is at least about 20 kW at the fiber bottom holeassembly connection.
 59. The system of claim 55, wherein the laser beamis at least about 15 kW at the fiber bottom hole assembly connection.60. The system of claim 55, wherein the laser source is at least about20 kW.
 61. (canceled)
 62. The system of claim 55, wherein the bottomhole assembly comprises a motor.
 63. The system of claim 55, wherein thesurface of the borehole comprises a bottom surface of the borehole. 64.The system of claim 55, wherein the bottom hole assembly comprises anelectric motor.
 65. The system of claim 55, wherein the bottom holeassembly comprises a means for transferring rotational motion.
 66. Asystem for forming a borehole in the earth comprising: a. a high powerlaser source; b. a laser delivery assembly; c. an optical fibercomprising; i. a first and a second end; ii. a length between the firstand second ends; iii. the first end being optically associated with thelaser source; and, iv. the fiber having a length of at least about 1000ft; d. a means for delivering a laser beam from the laser source to asurface of the borehole, wherein the means includes a beam powerdeposition optic having a property of changing an energy distributionprofile within the laser beam; and; e. the laser delivery meansconnected to and optically associated with the second end of the opticalfiber; f. a means for providing a substantially uniform energydeposition; and, g. the laser delivery means comprising the means forproviding the substantially uniform energy deposition.
 67. The system ofclaim 66, wherein the laser delivery means comprises an opticalassembly.
 68. The system of claim 66, wherein the laser delivery meansis contained within the laser delivery assembly.
 69. The system of claim66, wherein the laser delivery means is contained within the laserdelivery assembly and the laser delivery assembly comprises a rotatingoptical assembly.
 70. The system of claim 66, wherein the laser deliveryassembly comprises an electric motor.
 71. The system of claim 66,wherein the laser source provides more than one laser beam.
 72. Thesystem of claim 66, wherein the surface of the borehole comprises abottom surface of the borehole.
 73. The system of claim 66, wherein thelaser beam has a substantially uniform profile at the fiber second end.74. The system of claim 66, wherein the laser beam is at least about0.15 kW at the fiber second end.
 75. The system of claim 66, wherein thelaser source is from at least about 40 kW.
 76. The system of claim 66,wherein the laser source is at least about 25 kW.
 77. A system forcreating a borehole comprising: a. a high power laser source; b. abottom hole assembly; c. a fiber optically connecting the laser sourcewith the bottom hole assembly, such that a laser beam from the lasersource is transmitted to the bottom hole assembly; d. a means forproviding the laser beam to a surface of the borehole; and, e. a beampower deposition optic having a property of changing an energydistribution profile within the laser beam; f. the bottom hole assemblycomprising: i. the means for providing the laser beam to the surface ofthe borehole; ii. the providing means comprising the beam powerdeposition optic; and, iii. the means for providing the laser beam tothe bottom surface configured to provide a predetermined energydeposition profile; g. wherein, the laser beam as delivered from thebottom hole assembly illuminates the surface of the borehole with apredetermined energy deposition profile.
 78. The system of claim 77,wherein the predetermined energy deposition profile is biased toward anoutside area of a bottom surface of the borehole surface.
 79. The systemof claim 77, wherein the predetermined energy deposition profile isbiased toward an inside area of a bottom surface of the boreholesurface.
 80. The system of claim 77, comprising a mechanical removalmeans.
 81. The system of claim 77, wherein the laser beam at the bottomhole assembly has a power of at least about 15 kW.
 82. A system foradvancing a borehole in the earth comprising: a. a high power lasersource; b. a bottom hole assembly; and, c. a fiber optically connectingthe laser source with the bottom hole assembly, such that a laser beamfrom the laser source is transmitted to the bottom hole assembly; d. thebottom hole assembly comprising: a means for providing a laser beam to abottom surface of the borehole in a predetermined pattern, wherein themeans for providing it laser beam to a bottom surface of the boreholefurther comprises a means for changing an energy distribution profilewithin the laser, an wherein the predetermined pattern is configured toilluminate a majority of the borehole bottom surface and in apredetermined energy deposition profile.
 83. The system of claim 82,wherein the laser beam at the bottom hole assembly has a power of atleast about 15 kW.
 84. A system for creating a borehole comprising: a. ahigh power laser source; b. a bottom hole assembly; and, c. a fiberoptically connecting the laser source with the bottom hole assembly,such that a laser beam from the laser source is transmitted to thebottom hole assembly, the laser beam at the bottom hole assembly havinga power of at least about: 5 kW; d. the bottom hole assembly comprising:a means for providing it substantially elliptical shaped laser beam spothaving a power of at least about 5 kW to the bottom surface of theborehole in a rotating manner to thereby provide a predetermined energydeposition profile to the bottom surface of the borehole.
 85. A methodof forming a borehole using a laser, the method comprising: a. advancinga high power laser beam transmission fiber into a borehole; i. theborehole having a bottom, a side wall, a top opening, and a lengthextending between the bottom and the top opening of at least about 5000feet; ii. the transmission fiber comprising a distal end, a proximalend, and a length extending between the distal and proximal ends, thedistal end being advanced into the borehole; iii. the transmission meanscomprising a means for transmitting high power laser energy, b.providing a laser beam, having a power of least about 10 kW, to theproximal end of the transmission fiber; c. transmitting the power of thelaser been down the length of the transmission fiber so that the beamexits the distal end, having a first energy distribution profile, andenters a laser delivery assembly; and, d. directing the laser beam,having a power of at least about 5 kW, and having the second energydistribution profile, in a predetermined pattern defining a patternarea; and, wherein the predetermined pattern provides a predeterminedand substantially uniform energy deposition profile to a surface of theborehole, whereby the borehole is completed, in part, based upon theinteraction of the laser beam with the surface of the borehole.
 86. Asystem for creating a hole comprising: a. a high power laser sourcegenerating a high power laser beam, b. a bottom hole assemblycomprising: a means for providing the high power laser beam to a bottomsurface of a borehole, wherein the means for providing the high powerlaser beam comprises beam power deposition optics; c. a fiber opticallyconnecting the high power laser source with the bottom hole assembly,such that the high power laser beam from the high power laser source istransmitted to the bottom hole assembly, the high power laser beam atthe bottom hole assembly having a power of at least about 1 kW; d.wherein, the high power laser beam as delivered from the bottom holeassembly illuminates a bottom surface of the borehole with the highpower laser beam having a power of at least about 0.1 kW in asubstantially even energy deposition profile on the bottom surface. 87.The system of claim 86, wherein the laser bottom hole assembly comprisesa housing defining a cavity.
 88. A system for creating a borehole in theearth comprising: a. a high power laser source; b. a bottom holeassembly; c. an optical fiber comprising: i. a first end and a secondend; ii. a length between the first and second ends that is at least1000 ft; and, iii. the first end being optically associated with thelaser source; d. a means for delivering a laser beam from the lasersource to a surface of the borehole, wherein the means for delivering alaser beam comprises a means for providing a substantially uniformenergy deposition to the bottom of the borehole and is connected to andoptically associated with the second end of the optical fiber.
 89. Asystem for creating a borehole in the earth comprising: a. a high powerlaser source; b. a bottom hole assembly; and, c. a fiber opticallyconnecting the high power laser source with the bottom hole assembly,such that a high power laser beam from the laser source is transmittedto the bottom hole assembly, the high power laser beam in the fiberhaving a power of at least about 5 kW; d. the bottom hole assemblycomprising: a means for providing a laser beam shot pattern to an areaof the borehole in a predetermined shot pattern configured to illuminatea majority of the area with a laser beam having a power of at leastabout 5 kW and in a predetermined energy deposition profile to the area.90. A system for creating a borehole in the earth comprising: a. a highpower laser source; b. a bottom hole assembly; and, c. a fiber opticallyconnecting the high power laser source with the bottom hole assembly,such that a high power laser beam from the laser source is transmittedto the bottom hole assembly, the high power laser beam in the fiber atthe fiber having a power of at as about 5 kW; d. the bottom holeassembly comprising: a means for providing a substantially ellipticalshaped laser beam spot having at power of at least about: 5 kW to thebottom surface of the borehole in a rotating manner to thereby provide apredetermined energy deposition to the bottom surface of the borehole.91. A method of forming a borehole using a laser, the method comprising:a. advancing a transmission fiber into a borehole; i. the boreholehaving a bottom surface, a top opening, and a length extending betweenthe bottom surface and the top opening of at least about 1000 feet; ii.the transmission fiber comprising a distal end, a proximal end, and alength extending between the distal and proximal ends, the distal endbeing advanced down the borehole; b. providing a laser beam, having at:least about 10 kW, to the proximal end of the transmission means; c.transmitting the power of the laser beam down the length of thetransmission fiber so that the beam exits the distal end and enters alaser bottom hole assembly; and, d. directing the laser beam, having atleast about 5 kW, in a predetermined pattern to provide a predeterminedand substantially uniform energy deposition profile to the surface ofthe borehole whereby the length of the borehole is increased, in part,based upon the interaction of the laser beam with the bottom of theborehole.
 92. A system for creating a hole comprising: a. a high powerlaser source generating a high power laser beam; b. a laser deliveryassembly comprising: an optics configuration capable of providing thehigh power laser beam to a bottom surface of a borehole, wherein theoptics configuration comprises beam power deposition optics; c. a fiberoptically connecting the high power laser source with the laser deliveryassembly, such that the high power laser beam from the high power lasersource is transmitted to the laser delivery assembly, the high powerlaser beam at the laser delivery assembly having a power of at leastabout 1 kW; d. wherein, the high power laser beam as delivered from thebottom hole assembly illuminates a bottom surface of the borehole withthe high power laser beam having a power of at least about 1 kW in asubstantially even energy deposition profile on the bottom surface. 93.A system for creating a borehole in the earth comprising: a. a highpower laser source; b. a bottom hole assembly; an optical fibercomprising: a first end and a second end; a length between the first andsecond ends that is at least 1000 ft; the first end being opticallyassociated with the laser source; d. a laser delivery assembly capableof delivering a laser beam from the laser source to a surface of theborehole, wherein the laser delivery assembly comprises a means forproviding a substantially uniform energy deposition to the bottom of theborehole and is connected to and optically associated with the secondend of the optical fiber.
 94. A system for creating a borehole in theearth comprising: a. a high power laser source; b. a bottom holeassembly; and, c. a fiber optically connecting the high power lasersource with the bottom hole assembly, such that a high power laser beamfrom the laser source is transmitted to the bottom hole assembly, thehigh power laser beam in the fiber having a power of at least about 5kW; d. the bottom hole assembly comprising: an optical assembly capableof providing a laser beam shot pattern to an area of the borehole in apredetermined shot pattern configured to illuminate a majority of thearea with a laser beam having a power of at least about 5 kW and in apredetermined energy deposition profile to the area.
 95. The system ofclaim 94, wherein the optical assembly contains a beam power depositionoptic having a property of changing an energy distribution profilewithin the laser beam.